Ceiling debris collection bin

ABSTRACT

The Ceiling Debris Collection Bin is a receptacle with a wide opening that facilitates the nearly complete collection of acoustic ceiling debris removed by the Popcorn Ceiling Scraper—U.S. Pat. No. 6,101,663. The makers this Scraper recommend use of a plastic trash bag for collection of debris but a trash bag is not efficient enough, being limited to an opening defined by the scraper&#39;s flexible band. The new Ceiling Debris Collection Bin is very efficient owing to the flared side design. Debris that flies all over and might escape collection by a trash bag would be captured by this uniquely designed Ceiling Debris Collection Bin with nearly three times the collection area. The collapsible wings of the bin accommodate the flexible metal band of the Popcorn Ceiling Scraper, so that the Scraper can be pushed up to where the ceiling meets the wall.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OF DEVELOPMENT

Not Applicable

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX

Not applicable

BACKGROUND OF INVENTION

There is an existing product in use called the Popcorn Ceiling Scraper, U.S. Pat. No. 6,101,663, distributed by Homex Products, Incorporated. The makers of this product currently recommend the use of a plastic trash bag for use with their scraper as a collection receptacle. The bag is attached to the flexible band part of their scraper to facilitate the collection of acoustic ceiling debris removed from a ceiling by the scraper. This new invention, the Ceiling Debris Collection Bin, is designed for use with the Popcorn Ceiling Scraper and is a superior replacement of the plastic trash bag.

Prior to removing material from a ceiling, it is recommended that the ceiling be moistened to facilitate easier removal of the material. If the ceiling material is not sufficiently wet or drying occurs prior to removal, it tends to scatter upon contact with the scrapper blade. The design of the Ceiling Debris Collection Bin controls the scattering and catches and retains the removed acoustic ceiling debris, whether wet or dry. It is much more efficient than a plastic trash bag and is a preferred alternative.

BRIEF SUMMARY OF THE INVENTION

The Ceiling Debris Collection Bin is constructed of sturdy single wall corrugated cardboard. It is attached to the metal band portion of the Popcorn Ceiling Scraper by the use of four nylon cable ties. The unique design of this new invention, with flared front and rear sides, creates a much larger collection opening and surface than an ordinary plastic trash bag, and the slant wall design directs the removed acoustic ceiling material down into the lower box.

A trash bag has an opening limited to thirty-six (36) square inches (232.26 square cm) which is determined by the area encompassed by the flexible metal band part of the scraper. The Ceiling Debris Collection Bin has an opening of about ninety (90) to ninety-six (96) square inches (580.64 to 619.35 sq. cm), depending on the width of the lower box. The side front wings are collapsible when the Ceiling Debris Collection Bin is pushed against the wall and straighten when pulled away from the wall, returning the Ceiling Debris Collection Bin to its original shape. This feature accommodates the flexible metal band movement of the scraper. The foam rubber wedges on both sides of the Ceiling Debris Collection Bin have a sloped top surface that assists in the debris collection process, by directing debris into the Ceiling Debris Collection Bin. The Ceiling Debris Collection Bin is far more efficient than a common plastic trash bag and is a superior alternative. The Ceiling Debris Collection Bin is a disposable product.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 shows the complete Ceiling Debris Collection Bin invention.

FIG. 2 is a view looking down into the Ceiling Debris Collection Bin.

FIG. 3 shows the inside of the right end cap, a unique design made of cardboard that transforms a certain box structure into the Ceiling Debris Collection Bin.

FIG. 4 shows the outside of the left end cap.

FIG. 5 shows the right end cap lined up to the right end flap before attachment.

FIG. 6 shows the right foam rubber wedge. There are two of these wedges, one each for the right and left wings. They are exactly alike and they facilitate the collapsing and rebounding of the wings as the Ceiling Debris Collection Bin is pushed up against the wall where the ceiling meets it.

FIG. 7 is a side view of the same right foam rubber wedge.

FIG. 8 shows the Ceiling Debris Collection Bin prior to assembly. It stores, packs and ships flat. The consumer simply folds it out and makes the appropriate connections where two sided tape is affixed to the various flaps.

FIG. 9 shows the right rear corner of the Ceiling Debris Collection Bin. It shows the right rear connector flap prior to being folded over and connected to the rear side flap.

FIG. 10 shows the Ceiling Debris Collection Bin in relation to the Popcorn Ceiling Scraper, U.S. Pat. No. 6,101,663.

FIG. 11 shows the Ceiling Debris Collection Bin connected to the Popcorn Ceiling Scraper, U.S. Pat. No. 6,101,663. This connection is facilitated by the use of cable ties.

FIG. 12 shows the Ceiling Debris Collection Bin in use. Note that the right front wing flattens as it makes contact with the wall.

DETAILED DESCRIPTION OF THE INVENTION

It is suggested that FIG. 1 be included on the front page of the patent application publication and patent.

FIG. 1 shows the Ceiling Debris Collection Bin 2, which is designed for use with an existing product already in the marketplace known as the Popcorn Ceiling Scraper 48, U.S. Pat. No. 6,101,663 shown in FIG. 10. The Ceiling Debris Collection Bin 2 is constructed of sturdy single wall corrugated cardboard with a recommended minimum 200 lb. (90.72 kg) test rating. Construction begins as a box structure consisting of a lower box 1, including two end flaps—a right end flap 5 seen in FIG. 1 and FIG. 2 and a left end flap 9 shown in FIG. 2 and two side flaps—a rear side flap 7 and a front side flap 3 seen in FIG. 1. The right end flap 5, shown in FIG. 1, has two eyelets—a right end flap front eyelet 4 and a right end flap rear eyelet 6.

FIG. 2 is a top view looking down into the Ceiling Debris Collection Bin 2 and shows the left end flap 9 and the left end flap front eyelet 10 and the left end flap rear eyelet 8. It also shows another view of the right end flap 5. All eyelets are positioned five-eighths (0.625) inches (1.59 cm) from the top of the end flaps 5 and 9, measured to the top rims of the eyelets 4 and 6, (FIGS. 1), and 8 and 10 (FIG. 2). It also illustrates the much expanded opening for collection of debris. The Ceiling Debris Collection Bin has an opening of about ninety (90) to ninety-six (96) square inches (580.64 to 619.35 sq. cm), depending on the width of the lower box.

In FIG. 1 the right end flap front eyelet 4 and the right end flap rear eyelet 6 are spaced three (3) inches (7.62 cm) apart measured center to center and equidistant from an imaginary vertical center line of the right end flap 5.

In FIG. 2 the left end flap front eyelet 10 and the left end flap rear eyelet 8 are spaced three (3) inches (7.62 cm) apart measured center to center and equidistant from an imaginary vertical center line of the left end flap 9.

The eyelets accommodate cable ties 50, 51, 52, and 53, which are an existing product shown in FIG. 11, and which attach the Ceiling Debris Collection Bin 2 to the Popcorn Ceiling Scraper 48 shown in FIG. 11.

The right end cap 11 is shown in FIG. 3 and the left end cap 26 is shown in FIG. 4. These end caps, 11 and 26, are unique in that their attachment to a proper box transforms the box into the Ceiling Debris Collection Bin 2 shown in FIG. 1.

The right center section 13, seen from the inside in FIG. 3, has two eyelets—the right front eyelet 12 and the right rear eyelet 14. Eyelets 12 and 14 are positioned five-eighths (0.625) inches (1.59 cm) from the top of the center section 13 measured to the top rims of eyelets 12 and 14.

The right front eyelet 12 and the right rear eyelet 14 are spaced three (3) inches (7.62 cm) apart measured center to center and equidistant from an imaginary vertical center line dividing the right center section 13.

The right rear wing 15 is shaped like an isosceles triangle with the vertical leg 16 and opposing leg 17 having a length of four (4) inches (10.16 cm) each. The vertex angle 18 is thirty degrees (30°). The shape of the right rear wing 15 allows for a wider opening and greater collection area for debris scraped off the ceiling.

The right rear connector flap 19 is rectangular in shape and measures 1″×4″ (2.54 cm×10.16 cm) and facilitates, in conjunction with the other connector flaps, the assembly of the Ceiling Debris Collection Bin 2 (FIG. 1) when unfolded, by means of appropriately placed two sided tape.

The right front connector flap 20 and right front wing 21 have the mirror image configuration as the right rear connector flap 19 and right rear wing 15, respectively. The right front connector flap 20 is rectangular in shape and measures 1″×4″ (2.54 cm×10.16 cm). The right front wing 21 is shaped like an isosceles triangle with the vertical leg 23 and opposing leg 24 having a length of four (4) inches (10.16 cm) each. The vertex angle 25 is thirty degrees) (30°). The shape of the right front wing 21 allows for a wider opening and greater collection area for debris scraped off the ceiling.

An additional part is the right foam rubber wedge 22 that is glued to the inner surface of the right front wing 21. The right front wing 21 is creased down the middle to the center of the vertex angle 25 to allow the wing to collapse when it comes in contact with the wall where the ceiling meets the wall. The right foam rubber wedge 22 assists the right front wing 21 to rebound back into shape.

The left end cap 26 is shown in FIG. 4. The left center section 28 has two eyelets—the left front eyelet 27 and the left rear eyelet 29. These eyelets 27 and 29 are positioned 0.625 inches (1.59 cm) from the top of the left center section 28 measured down to the top of the eyelets. The left front eyelet 27 and the left rear eyelet 29 are spaced three inches apart center to center and are equidistant from an imaginary vertical center line dividing the left center section 28.

The left rear wing 30 is shaped like an isosceles triangle with the vertical leg 31 and opposing leg 32 having a length of four (4) inches (10.16 cm). The vertex angle 33 is thirty degrees (30°). The shape of the left rear wing 30 allows for a wider opening and greater collection area for debris scraped off the ceiling.

The left rear connector flap is a rectangle measuring 1″×4″ (2.54 cm×10.16 cm) and helps to facilitate the connection of the left end cap 26 to the rear side flap 7 shown in FIG. 1.

The left front connector flap 35 and left front wing 36 have the mirror image configuration as the left rear connector flap 34 and left rear wing 30, respectively. The left front connector flap 35 is a shaped like a rectangle measuring 1″×4″ (2.54 cm×10.16 cm). The left front wing 36 is shaped like an isosceles triangle with the vertical leg 38 and opposing leg 39 having a length of four (4) inches (10.16 cm). The vertex angle 40 is thirty degrees (30°). The shape of the left front wing 36 creates a wider opening and greater collection area for debris scraped off the ceiling.

An additional part is the left foam rubber wedge 37 that is glued to the inner surface of the left front wing 36. The left front wing 36 is creased down the middle to the center of the vertex angle 40 to allow the wing to collapse when it comes in contact with the wall where it meets the ceiling. The left foam rubber wedge 37 assists the left front wing 36 to rebound back into shape.

FIG. 5 shows the right end cap 11 being lined up for attachment to the outside of the right end flap 5 of the box. Eyelets 12 and 14 of the right center section 13 are lined up with eyelets 4 and 6, respectively, of the right end flap 5. The two parts are then glued together with proper adhesive for gluing cardboard. The left side is assembled in the same fashion. Once the end caps are attached to the end flaps, the eyelets may be reinforced with either metal or plastic eyelets which will accommodate the cable tie width of 0.10 inch (0.254 cm). This is simply an option.

FIG. 6 shows the right foam rubber wedge 22 prior to attachment to the right front wing 21 as seen in FIG. 3. The right foam rubber wedge 22 is shaped like an isosceles triangle with the two legs (opposing sides) having a length of four (4) inches (10.16 cm) and a vertex angle 41 of thirty degrees (30°).

FIG. 7 is a side view of the right foam rubber wedge 22. The top portion is cut to an angle 42 of thirty degrees (30°) resulting in a downward slope of the top surface 43 of sixty degrees (60°). This slope facilitates the collection of additional ceiling debris by directing the debris down into the Ceiling Debris Collection Bin 2 seen in FIG. 2. The left side foam rubber wedge is the same cut.

A market ready Ceiling Debris Collection Bin 2 is seen in FIG. 8. This packs flat and simply needs to be folded out, closure flaps 44, 45, 46, and 47 (46 and 47 are obscured from view) folded over and secured with two sided tape already affixed at the factory. A recommended tape is 3M Double Sided Extended Liner Tape or one of similar quality.

FIG. 9 shows the right rear connector flap 19 prior to connection with the right side of the rear side flap 7. This connection is accomplished by the use of two sided tape of the kind previously described. The right rear connector flap 19 is simply folded over onto the rear side flap 7 and connected. Another option is to have the connector flaps fold inside of the front and rear side flaps. This would increase the collection opening by about three (3) square inches (19.35 sq. cm).

FIG. 10 shows the entire Ceiling Debris Collection Bin 2 prior to connection to the Popcorn Ceiling Scraper 48, an existing product in the marketplace—U.S. Pat. No. 6,101,663, dated Aug. 15, 2000. The joining of the two products is illustrated in FIG. 11. This is accomplished by the use of four cable ties 50, 51, 52, and 53, another product already on the market and in wide use. It is recommended to use cable ties with a length of four (4) inches (10.16 cm) and a width of 0.10 inch (0.254 cm) with test strength of 18 lbs. (8.16 Kg). These ties run through the eyelets and are secured to the flexible metal band part 49 of the Popcorn Ceiling Scraper 48.

FIG. 12 illustrates the entire apparatus scraping a ceiling. Note how the right front wing 22 collapses to accommodate travel of the Ceiling Popcorn Scraper 48 to the ceiling's edge where it meets the wall.

The following inside dimensions are recommended for the lower box section of the Ceiling Debris Collection Bin:

-   -   Length of lower box section: 12″ (30.48 cm)     -   Height of lower box section: 4″-5″ (10.16-12.7 cm)     -   Width of lower box section: 3.5″-4″ (8.89-10.16 cm)     -   Length of front and rear side flaps: 12″ (30.48 cm)     -   Height of front and rear side flaps: 4″ (10.16 cm)     -   Length of left and right side flaps: 3.5″-4″ (8.89-10.16 cm)     -   Height of left and right side flaps: 4″ (10.16 cm)     -   Length of front and rear closure flaps: 12″ (30.48 cm)

Height of front and rear closure flaps: 3.5″-4″ (8.89-10.16 cm)

Length of right and left side closure flaps: 3.5″-4″ (8.89-10.16 cm)

Height of right and left side closure flaps: 4″ (10.16 cm) The following dimensions are recommended for the end caps:

Center section length: 3.5″-4″ (8.89-10.16 cm) Center section height: 4″ (10.16 cm)

All wings (front and rear, left and right) are shaped like isosceles triangles with the two legs 4″ (10.16 cm) each, the vertex angle 30° and the corresponding base 2.07″ (5.26 cm).

All connector flaps (front left and right and rear left and right) are shaped as rectangles with dimensions of 1″×4″ (2.54 cm×10.16 cm).

The foam rubber wedges are shaped like isosceles triangles with the two legs 4″ (10.16 cm) each, the vertex angle 30° and the corresponding base 2.07″ (5.26 cm), which dimensions conform to the left and right front wings. The recommended thickness of the foam rubber is 0.5″ (1.27 cm), but this could vary. The top of the foam rubber wedge is cut to form a 60° slope down into the bin. The suggested material for these wedges is an open cell foam such as Charcoal Firm Foam, with a density of 1.7 lb./cubic ft., or WesLastomer™ Grade 5500 Soft Open Cell Sponge, with an average density of 7.33 lb./cubic ft. or some similar product.

The eyelets are placed 0.625″ (1.59 cm) below the top of the center section measured to the top of the eyelets. They are centered and spaced 3″ (7.62 cm) apart measured center to center. The eyelets have a minimum diameter of 0.125″ (0.32 cm). A second embodiment of the Ceiling Debris Collection Bin would not have the flexible front wings and therefore no foam wedges, but would otherwise be the same in all other aspects as the first embodiment. Removal of the ceiling texture material next to the wall would then be accomplished with a putty knife, which is required for the corners anyway.

There may slight variations in the dimensions and materials due to manufacturing requirements and processes which would not alter the basic design or function of the Ceiling Debris Collection Bin. For example, the connector flaps illustrated in the drawings are shown connecting to the outside of the front and rear side flaps. A second option would be for these connector flaps to connect to the inside of the front and rear side flaps adding about three (3) square inches (19.35 sq. cm) to the collection opening.

The eyelets may also be reinforced with either metal or plastic eyelets which will accommodate the cable tie width of 0.10 inch (0.254 cm). This is an option and not a requirement. 

1. The Ceiling Debris Collection Bin is uniquely designed for use with the Popcorn Ceiling Scraper, U.S. Pat. No. 6,101,663, which currently uses a less efficient trash bag for collection of ceiling debris.
 2. The distinguishing feature of the Ceiling Debris Collection Bin is the unique design of the end caps with isosceles triangle shaped wings and rectangular connector flaps that affix to the ends of the bin and transform an appropriate box into the Ceiling Debris Collection Bin.
 3. The flared front and rear sides of the Ceiling Debris Collection Bin create a collection opening of ninety to ninety-six, 90-96 square inches (580.64-619.35 sq. cm)—about two and a half times that of a trash bag, which is limited by the area encompassed by the flexible metal band of the Scraper.
 4. The side wings of the Ceiling Debris Collection Bin are collapsible to accommodate the flexible metal band of the Popcorn Ceiling Scraper, allowing the Scraper to move up to where the ceiling meets the wall.
 5. The collapsible side wings (claim 4) compress when pushed against the wall.
 6. There are no other moving parts. 